Weatherized minerals and methods of making and using same

ABSTRACT

A weatherized mineral mixture is produced by heating a digestible fat or fatty acid and spraying a mineral mixture with the heated digestible fatty acid to form a protective layer over the mineral mixture. The weatherized mineral mixture may be free of salts of fatty acids, namely soaps. The weatherized mineral mixture sheds water and is wind-resistant. Upon ingestion by livestock animals, the protective coating is digested and the minerals within the mineral mixture are absorbed by the livestock animal.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/893,104 filed Jun. 4, 2020, which is a continuation of U.S. patentapplication Ser. No. 15/337,849 filed Oct. 28, 2016, issued as U.S. Pat.No. 10,709,154 on Jul. 14, 2020, which is a continuation of U.S. patentapplication Ser. No. 13/765,298 filed Feb. 12, 2013, issued as U.S. Pat.No. 9,504,269 on Nov. 29, 2016, which claims benefit to U.S. ProvisionalApplication No. 61/598,505 filed Feb. 14, 2012, the contents of all areincorporated by reference in their entireties.

FIELD OF THE INVENTION

Implementations provide weatherized minerals with a digestibleprotective coating and methods of making and using the weatherizedminerals in free-choice mineral applications.

BACKGROUND

Free-choice minerals are generally loose minerals placed in an opencontainer in pasture. Livestock animals, such as beef and dairy cattle,consume the free-choice minerals intermittently while grazing inpasture. When the free-choice minerals are exposed to environmentalfactors such as wind and rain, loss may occur. Wind may blow away theminerals or rain may cause trace minerals to leech from the mineralmixture. In some cases, when the minerals are exposed to rain, theminerals become wet and may cake-up preventing flow.

Free-choice minerals may be protected from wind and rain by forming afirst protective soap coating over cores and a second protective coatingover the soap coating. The soap is generally formed by adding a metaloxide to the minerals and then reacting the metal oxide with a fattyacid. This process of forming soap may be problematic because reactingthe metal oxide provided on or in the minerals with the fatty acid orpetrolatum may result in inconsistent or incomplete hydrolysis, whichmay result in the coated particles sticking or caking. The secondprotective coating, such as petrolatum, is applied over the soapcoating. However, prior to applying the protective coating, thesoap-coated particles generally require dusting to prevent caking orsticking of the otherwise sticky, non-flowing soap-coated particles.

Coating minerals with multiple protective layers as provided above canbe problematic because the minerals may remain protected within thedigestive system of the livestock animal and may not be digested orabsorbed. In addition, petrolatum is a non-digestible substance andprovides no benefit to the animal. Observing a livestock animalingesting these protected minerals may also be misleading for a farmeror a nutritionist that believes the livestock animal is benefiting fromingesting the protected free-choice minerals, when the livestock animalis not actually receiving the intended benefits.

SUMMARY

Implementations herein address the problems above by providingweatherized or weather-protected mineral mixture products that include aprotective layer of fat, such as a digestible fat, as well as methods ofmaking and using the weatherized mineral mixture products.

In certain implementations, a method of forming a weatherized mineralmixture free of salts of fatty acids, e.g., soap, includes heating a fatand spraying a mineral mixture with the heated fat to form a protectivelayer over the mineral mixture.

In another implementation, a method of forming a weatherized mineralmixture involves spraying a flowable digestible fat over a mineralmixture to form a protective layer over a first portion of the mineralmixture. A second portion of the mineral mixture is substantially freeof the protective layer. The method continues by spraying an oil overthe mineral mixture portions to incorporate the second portion onto theprotective layer overlying the first portion.

In yet another implementation, a weatherized mineral mixture includes amineral mixture with a protective layer formed over the mineral mixturethat is composed of a fat and is free of salts of fatty acids.

In further implementations, a method of providing livestock animals withfree-choice minerals includes providing the livestock animals with aweatherized mineral mixture formed of a mineral mixture coated with afat, where the weatherized mineral mixture is free of salts of fattyacids and where minerals in the mineral mixture are absorbed by thedigestive system of the livestock animal.

In still further implementations, a method of forming aweather-resistant, anti-caking mineral mixture involves heating adigestible fat to form a flowable, digestible fat; and spraying amineral mixture with the flowable, digestible fat to provide aprotective layer over the mineral mixture to form the weather-resistant,anti-caking mineral mixture, where the weather-resistant, anti-cakingmineral mixture is free of salts of fatty acids.

In yet further implementations, a method of forming a weather-resistant,anti-caking mineral mixture involves spraying a flowable digestible fatover at least a first portion of a mineral mixture to form a protectivelayer over the first portion; providing a second portion of the mineralmixture that is substantially free of the protective layer; and sprayingan oil over the first and second mineral mixture portions to incorporatethe second portion onto the protective layer overlying the first portionto provide the weather-resistant, anti-caking mineral mixture, where theweather-resistant, anti-caking mineral mixture is free of salts of fattyacids.

In some implementations, a weather-resistant, anti-caking mineralmixture includes mineral mixture particles with a protective layer inwhich the protective layer comprises a fat, and where theweather-resistant, anti-caking mineral mixture is free of salts of fattyacids.

DESCRIPTION OF THE DRAWING

FIG. 1 illustrates a flow diagram of a production system for formingweatherized minerals, according to certain implementations.

DETAILED DESCRIPTION

Weatherized minerals provided herein include a protective coating of fatsurrounding mineral particles. The weatherized minerals may be formed byspraying digestible fats over mineral and nutrient particles. Theprotected minerals and nutrients may be weather-resistant, flowable andmay have a shiny or wet appearance. In some implementations, a flowableoil coating such as mineral oil may coat the exterior of the fat-coatedprotected mineral particles. Livestock animals in pasture may ingest theprotected minerals and the subsequent digestion or absorption of thefats and mineral particles may provide dietary benefits to the livestockanimal that may otherwise not be realized using other forms of protectedminerals with coatings of non-digestible material. Accordingly, thedigestible fat not only protects the minerals and nutrients fromenvironmental factors such as wind, rain and snow, but also provides anenergy source, unlike other forms of protected minerals that usenon-digestible petrolatum.

Fats used to coat the minerals and nutrients may be in the form of highmelting point fats that are substantially solid at room temperature.High melting point fats may include palm stearin, palm fat, palmstearin, coconut oil, lauric acid, palm itic acid, palmitoleic acid,animal fats such as beef tallow and pork fat and combinations thereof.The high melting point fats may be digestible and may be known a freefatty acids or triglyceride fatty acids. High melting point fats mayprovide advantages over fats that are liquid at ambient temperatures dueto the fat with a low melting point having a propensity to go rancid inthe presence of minerals. Fats such as palm fat may be composed of atleast 98 percent fat, and may include combinations of one or more ofpalmitic acid, stearic acid and oleic acid. For example, the digestiblefat may include palmitic acid between about 40 to 75 percent; betweenabout 40 and 55 percent; between about 55 to 70 percent with the balanceincluding one or a combination of stearic and oleic acid. In someimplementations, other fats such as unsaturated fats may be provided inthe weatherized mineral composition. Other high melting point anddigestible fat sources may be used in accordance with the presentdisclosure and are not limited to those enumerated herein. In someimplementations, the fats used in the weatherized minerals may be freeor substantially free of non-digestible petrolatum.

As discussed herein, mineral particles may include minerals andnutrients such as mineral mixtures of macronutrients, micronutrients,vitamins, minerals including macrominerals and trace minerals, pelletedminerals and combinations. Macronutrients may include dicalciumphosphate, salt, magnesium oxide and calcium carbonate. In someimplementations, magnesium oxide may be provided as a mineral. Looseminerals and nutrients, such as in the form of loose trace minerals, maybe included as a portion of the mineral particles. The mineral particlesgenerally may be provided in the form of mineral mixtures includingmixtures of various combinations of the enumerated mineral particles.For example, mineral mixtures may include mineral pellets, high saltformulas, salt, dicalcium phosphate, magnesium oxide, calcium carbonate(e.g., limestone) and combinations thereof. The mineral mixtures mayalso include loose trace minerals, flavor enhancers and colorants suchas iron oxide. In some implementations, the mineral particles andmineral mixtures may be free flowing and/or may be free of molasses. Inaddition, the mineral mixtures may be free or substantially free of soapforming metal oxides such as calcium oxide and magnesium oxide,discussed below.

Mineral pellets within the mineral particles and mineral mixtures may bemixtures of trace minerals and grain or grain components (e.g., wheat,wheat middlings, corn, cracked corn, barley, oats, and grain meals) incrumbled or pelleted form. The mineral pellets may be derived fromlarger, cylindrical pellets that may be broken apart or crumbled tosizes suitable for free-choice mineral applications. The larger,cylindrical pellets may be formed under high pressure causing thecomponents to bind together without requiring a liquid binder such asmolasses. However, some molasses may be provided in the mineral pellets.The mineral pellets may incorporate trace minerals, which may preventseparation of such trace minerals from the mineral mixture. The mineralpellets may be similar in size to the particle sizes of salt, dicalciumphosphate and limestone particles that are used in the mineral mixture(e.g., about 500 microns or about the size of pretzel salt particles).The mineral pellets generally may be free-flowing pellets that may befree of added fats. As a result, the mineral pellets may be easily mixedwith the other components of the mineral mixture without additionalprocessing as with some prior art weatherized mineral cores.

In some implementations, loose minerals may be provided in addition tothe mineral pellets when the mineral profile of the mineral pelletslacks or includes a lower amount of required nutrients for a livestockanimal. For example, beef cattle may require different minerals andnutrients compared to goats and the loose minerals (such as traceminerals, macro minerals or both) may be added to the mineral pellets tosupplement the mineral mixture.

In additional implementations, high salt formulas may be used in themineral mixture without mineral pellets.

In further implementations, the mineral particles and mineral mixturesmay be free or substantially free of certain metal oxides (such ascalcium oxide and magnesium oxide) or sodium hydroxide that may resultin the hydrolysis of the fats (e.g. fatty acid) forming the protectivecoating. In such implementations, formation of salts of fatty acids(i.e., soap) may be substantially prevented. In alternativeimplementations, metal oxides such as magnesium oxide may be included inthe mineral mixture as a nutrient, but due to the use of high meltingpoint fats such as triglycerides, the high melting point fats generallyslowly react with the metal oxide when the fat is in a flowable state,and is non-reactive upon solidifying. In such implementations, formationof salts of fatty acids may be substantially prevented. In addition oralternatively, the mineral particles and mineral mixtures may be free offatty acids and soaps prior to spray coating, described below. Providinga soap-free finished weatherized mineral product may provide a moredigestible coating and may enable the minerals and nutrients to beabsorbed and/or digested.

In yet further implementations, the fat-coated mineral particles andmineral mixtures may be coated with an additional liquid coating, suchas a mineral oil coating. The liquid outer coating may cause fines suchas loose minerals to be incorporated on the outside of the fat-coatedmineral particles. This may provide a weatherized mineral product with areduced amount of fines and a larger percentage of fat coated particlescompared to a weatherized mineral product without the additional liquidcoating. In this implementation, the fines adhered to the outside of thefat-coated particles may be readily available for absorption prior tothe breakdown or digestion of the fat coating. In addition or incombination with mineral oil, the additional liquid coating may beprovided with molasses, distillers solubles or other ingestible tacky,non-caking liquids that facilitate binding fines to the outside of thefat-coated mineral particles.

FIG. 1 illustrates a flow diagram of a production system 100 for formingweatherized minerals and nutrients according to some implementations. InFIG. 1, one or more fats, such as palm fat or coconut oil are providedin a vessel 110. The fat, which may be substantially solid at roomtemperature, may be heated in the vessel 110 to form a flowable oil 115.In some implementations, the vessel 110 may hold the flowable oil 115 ata temperature of about 140° F., at about 160° F., or between about 140°F. to about 160° F. or above.

The flowable oil 115 may be transferred by a pump 120 to a control valve130 for controlling the flow of the flowable oil 115 to a spray nozzle140. Upon reaching the spray nozzle 140, the flowable oil 115 may besprayed into a mixer 150 holding the mineral particles and mixturesdescribed above. As the mixer 150 rotates the sprayed, heated flowableoil 115 forms a coating over the mineral particles and mixtures.Spraying the heated oil into the mixer holding the mineral mixture mayprovide a more uniformly or evenly coated protective layer over mineralmixture compared to other methods that involve pouring petrolatum in amixer or the sequential application of a metal oxide followed by pouringpetrolatum to produce a soap reaction. The oil coating may harden or dryand provide free-flowing, fat-coated particles. In some implementations,the fat-coated particles may not be tacky, and therefore applying adusting agent may be unnecessary, while in other implementations, adusting agent may be applied. In further examples, the flowable oil 115may be free of soap-forming components such as sodium hydroxide andmetal oxides. Accordingly, the protected mineral mixture may be free ofor at least substantially free of salts of fatty acids (e.g., soap).

The coated mineral mixture exiting the mixer 150 may be provided as aweatherized mineral mixture. In some implementations, the fat coatingforming the weatherized mineral mixture may form about 2 percent of thetotal weight of the weatherized mineral mixture.

Further processing of the coated mineral mixture may involve applying aliquid coating such as mineral oil to the fat-coated mineral mixture.Referring to FIG. 1, a vessel 160 holding the liquid coating 170 may betransferred via a separate pump 180 and valve 190 to the spray nozzle140. The liquid coating 170 may be sprayed into the mixer 150 holdingthe coated mineral mixture. As the mixer 150 rotates, the liquid coating170 may be applied to the fat-coated mineral mixture as an outercoating. In further implementations, the liquid coating may be heatedprior to spray coating to provide a more flowable liquid, such as forhigher melting point liquid coatings.

In some implementations, the coated mineral mixture without the outerliquid coating may yield a certain amount of fines including loose traceminerals and macro minerals that are not incorporated into thefat-coated particles of the weatherized mineral mixture in the mixer150. Surprisingly, it has been found that by spraying the coated mineralmixture in the mixer 150 with the liquid coating 170, particularlymineral oil, the fines are incorporated onto the coated mineral mixture.The liquid coating 170 may thus facilitate binding of the fines to thefat coated mineral mixture, and the liquid coating may further form anouter coating over an inner coating of the fat-coated mineral mixturewith the fines of trace minerals and macro minerals arranged between thecoating layers. In some implementations, the coated mineral mixtureincludes an inner coating formed of a of fat that comprises 2 percent byweight of the mineral mixture, and the liquid coating forming the outercoating may be provided in a range between about 0.5 percent to about 2percent by weight of the mineral mixture. In addition, the liquidcoating 170 may enhance shine or may give the coated product a wet look.Generally, the liquid coating 170 does not impede digestion of thedigestible fatty acid coating.

In some implementations, the system 100 may maintain the flowable oil115 in a heated state until the flowable oil 115 exits the spray nozzle140. For example, once the oil is heated (e.g., heated in the vessel110, prior to reaching the vessel 110, or both), the heated flowable oil115 transfers through the system 100 while being maintained at atemperature of at least 140° F., such as by using insulated conduits orby heating the various components of the system 100. Maintaining thesystem 100 in a heated state may be beneficial for oils that do not flowat room temperature such as the digestible fats provided herein.

In use, the weatherized minerals provided herein, with or without theliquid coating 170, may be offered to livestock animals as free-choiceminerals in an open container. It has been found that the weatherizedminerals are wind resistant due to the fat coating adding bulk to themineral particles and mixtures. In addition, the fat coating sheds waterdramatically, thereby protecting the minerals from environmental factorssuch as rain and snow. In some implementations, the additional coatingmay shed water. In addition, the weatherized minerals exhibitanti-caking properties after being wetted.

When the weatherized minerals are ingested by livestock animals and passthrough their digestive tract, any trace or macro minerals atop thefatty acid coating are digested and absorbed, and upon breakdown ordigestion of the fat, the underlying minerals and nutrients within themineral mixture are digested and absorbed, thereby providing vitaminsand nutrients to benefit to the livestock animal. In addition, the fatcoating over the mineral mixture is digestible and therefore adds anenergy source for the livestock animal. In addition, in someimplementations, no petroleum by-products are consumed by the animalingesting the weatherized minerals provided herein. However, even whenthe additional liquid coating is provided as mineral oil, suchweatherized mineral products may provide benefits to the animal due tothe fines adhering to the outside of the fat-coated particles via themineral oil coating, making the fines available for absorption ordigestion substantially upon ingestion.

In some implementations, liquid ingredients such as molasses and otherorganic liquid byproducts typically used as a palatant (e.g., to provideodor and taste) may not be used in the methods of making the weatherizedminerals. This may reduce caking of the mineral mixture within themixer, associated equipment, and may reduce tackiness of the finalproduct. For example, molasses generally increases caking and may bedifficult to mix with the mineral particles and mixtures.

The following example provides weatherized mineral mixtures, which areillustrative and not limiting.

Example

Varying levels of mineral oil were provided as the liquid coating overthe fat-coated mineral particles and mixtures. Each of the weatherizedmineral mixtures tested included 2 percent palm fat (e.g., palm fat with65 percent palm itic acid) fat coating and 0 percent to 1.5 percentmineral oil outer coating in 0.5 percent increments.

In a twin shaft paddle mixer, the dry ingredients including iron oxideand trace minerals were mixed for one minute. The heated palm fat waspumped to nozzles positioned to spray the palm fat in the mixer. Thenozzles were steam purged while the mixer mixed the fat-coated particlesfor between about 30-45 seconds. Using the nozzles, mineral oil wassprayed into the mixer containing the fat-coated particles and mixed forone minute.

Surprisingly, there was a significant improvement in appearance as thelevel of mineral oil increased. The most dramatic improvements werebetween 0 percent and 0.5 percent and surprisingly between 1.0 percentand 1.5 percent. The 0 percent mineral oil weatherized mineral productlooked dry and dusty. As the level of mineral oil increased to 0.5percent and above, the apparent fines level decreased. At 1.5 percentmineral oil, the appearance of fines essentially disappeared, which wasunexpected. Providing a liquid coating such as mineral oil afterapplying the fat coating to the mineral mixture results in incorporationof the fines, which may provide a more desirable product as theincorporated fines on the outside of the fat-coated particles may beprevented from otherwise being carried away by wind.

Although the present disclosure provides references to preferredembodiments, persons skilled in the art will recognize that changes maybe made in form and detail without departing from the spirit and scopeof the invention.

What is claimed is:
 1. A weather-resistant, anti-caking mineral productfor livestock comprising: mineral particles; a digestible fat layer atopthe particles; and an oil coating atop the protective layer, saidweather-resistant, anti-caking mineral product being free of salts offatty acids.
 2. The product of claim 1, the oil coating formed ofmineral oil.
 3. The product of claim 1, the digestible fat being a highmelting point fat.
 4. The product of claim 3, the high melting point fatincluding at least one of: palm stearin, palm fat, coconut oil, lauricacid, palmitic acid, palmitoleic acid, or an animal fat.
 5. The productof claim 3, the high melting point fat being substantially solid at roomtemperature.
 6. The product of claim 1, the digestible fat being free ofa non-digestible petrolatum.
 7. The product of claim 1, the particlesbeing pellets.
 8. The product of claim 1, further comprising particlesfree of the digestible fat layer.
 9. The product of claim 8, theparticles free of the digestible fat layer including the oil coating,and the loose trace minerals or fines being adhered to the particlesfree of the digestible fat layer.
 10. The product of claim 9 arranged inan open container.
 11. The product of claim 1 arranged in an opencontainer.
 12. A weather-resistant, anti-caking mineral mixture productfor livestock comprising: mineral particles; a digestible fat layer atopa first portion of the particles; a second portion of the particles, thesecond portion being free of the digestible fat layer; an oil coatingatop the first and second portions of the particles, saidweather-resistant, anti-caking mineral mixture being free of salts offatty acids.
 13. The product of claim 12, the oil coating formed ofmineral oil.
 14. The product of claim 13, the mineral oil in an amountof about 0.5 to about 2.0 wt % of the product.
 15. The product of claim14, the digestible fat in an amount of about 2.0 wt % of the product.16. The product of claim 12, the digestible fat being a high meltingpoint fat.
 17. The product of claim 16, the high melting point fatincluding at least one of: palm stearin, palm fat, coconut oil, lauricacid, palmitic acid, palmitoleic acid, or an animal fat.
 18. The productof claim 12, the particles being free-flowing.
 19. The product of claim12 arranged in an open container.
 20. The product of claim 12, having ashiny or wet appearance.